- Engineered from rigid hexagonal-core kraft paperboard that absorbs heavy drops without plastic foam.
- Die-cut and layered for 1, 2-4, 5-12 or 13+ cavities with stepped depths and finger lift cutouts.
- Minimums depend on the product and are confirmed with your quote; standard turnaround is 10 to 14 business days (rush 4 to 5).
- Includes free structural engineering, custom dielines, digital proofs and 3D mockups before payment, plus free US shipping.
Custom Honeycomb Inserts
Custom honeycomb inserts die-cut from structural hex-cell kraft board to cushion heavy glass jars, candles, bottles, ceramics and electronics inside mailer and shipping boxes without plastic foam. Choose 1 to 13+ cavities in natural kraft or white-faced liners. Minimums depend on the product; we confirm yours with your quote. Ready in 10 to 14 business days with free US shipping.
What are custom honeycomb inserts?
Custom honeycomb inserts are rigid, plastic-free internal cushioning trays, bottle cradles and corner blocks die-cut from structural honeycomb paperboard - a sandwich panel built by bonding an internal core of hexagonal kraft paper cells between two flat outer linerboards. Inspired by the vertical load geometry of a natural beehive, those upright paper hex cells act like hundreds of miniature I-beams, delivering exceptional flatwise crush resistance and shock absorption at a fraction of the weight of solid timber or molded pulp. When a parcel drops in transit, the honeycomb walls compress progressively to protect heavy candle tumblers, glass dropper bottles, ceramic mugs and electronic appliances without a gram of expanded polystyrene or polyethylene foam. Unlike expandable honeycomb wrapping paper, structural honeycomb inserts arrive as thick, pre-cut trays ready to drop into your carton. Minimums depend on the product; we confirm yours with your quote.
Honeycomb inserts facts
- Minimum
- Confirmed with quote
- Turnaround
- 10-14 business days
- Rush
- 4-5 business days, quoted
- Material
- Structural hex-cell kraft core with paperboard liners
- Cavity counts
- 1, 2-4, 5-12 or 13+ custom die-cut cavities
- Liner faces
- Natural brown kraft, smooth white or printed top card
- Panel thickness
- Single-layer or multi-layer bonded depths
- Engineering
- Free structural design, CAD dieline & 3D mockup
- Shipping
- Free to all 50 states
Which custom honeycomb insert construction fits my product?
| Honeycomb style | Structure & build | Best products & box pairing | Visual look |
|---|---|---|---|
| Multi-layer stepped honeycomb tray | Die-cut honeycomb panels bonded over a solid base pad | Skincare jars, serum bottles and candle sets in mailers | Clean flat kraft or white top deck with stepped wells |
| Slotted fold-up honeycomb cradle | V-grooved or scored honeycomb sheet that folds around items | Single glass spirit bottles, olive oil and ceramic vases | Ships flat and folds into a 3D shock bumper in seconds |
| Two-piece honeycomb end caps | Thick left/right or top/bottom hex-cell blocks | Small kitchen appliances, audio gear, lamps and hardware | Direct curbside-recyclable replacement for EPS styrofoam |
| Printed card-topped honeycomb insert | CMYK or Pantone printed paperboard laminated to honeycomb | Retail gift sets, botanical PR kits and subscription boxes | Full-color graphics on top with heavy hex-cell cushioning below |
| Exposed-cell hexagonal display pad | Top liner peeled away inside or around the recess | Honey jars, beeswax candles, apothecary and organic brands | Showcases the geometric kraft honeycomb cells on opening |
Not sure which style fits?
Request a Quote →How are custom honeycomb inserts sized by cavity and panel thickness?
Structural honeycomb panels come in standard thicknesses (such as 0.4 in, 0.6 in, 0.8 in, 1.0 in and 1.5 in ) that can be used as a single pad or laminated into deeper blocks. We size the outer tray 1/16 to 1/8 inch under your box interior and keep at least 0.625 to 0.75 inches of hex-cell wall width around every pocket. Whether you are comparing honeycomb paperboard box inserts, die cut kraft honeycomb packaging pads, plastic free honeycomb bottle inserts, structural hex cell paper trays or custom honeycomb cushioning dividers, we size the template to your exact container.
| Outer tray size (L × W × D) | Cavity count & wall buffer | Typical protected product |
|---|---|---|
| 5 × 5 × 2 in | 1 cavity · 0.75 in hex perimeter | Single 9 oz or 12 oz glass candle tumbler or ceramic mug in a folding or mailer box |
| 8 × 6 × 2.5 in | 2 cavities · 0.625 in bridge wall | Glass facial oil dropper paired with a heavy frosted cream jar |
| 9 × 7 × 3 in | 3 cavities · stepped floor depths | Three-piece botanical skincare, essential oil or gourmet honey gift set |
| 10 × 9 × 4 in | 2 or 4 deep bottle cradles | 750 ml wine or spirit bottles, cold-pressed olive oil or artisan vinegar cruets |
| 12 × 9 × 3 in | 5 to 8 recessed pockets | Multi-jar spice sampler, apothecary ritual kit or ceramic tableware set |
| 16 × 12 × 4.5 in | 2-piece end caps or 12+ grid | Espresso makers, smart speakers, lighting fixtures or 12-jar wholesale shippers |
Have your inside dimensions ready? Request pricing across up to 3 quantities.
Request a Quote →How do I choose honeycomb inserts?
- Keep 0.625 to 0.75 in bridge wallsBecause honeycomb cores are made of discrete hexagonal cells, wider divider walls ensure at least two full hex cells sit between cavities.
- Pick exact-size or +1/32 in clearanceUnlike stretchy foam, kraft linerboard is firm; we cut cavities to exact product width or +1/32 in so jars slide in without scraping labels.
- Layer panels for stepped depthsBonding a die-cut top honeycomb panel over a solid bottom corrugated or honeycomb pad cushions bottom drops and levels uneven items.
- Add V-scores for flat-shipping cradlesFor high-volume bottle or appliance shipping, ask for scored honeycomb sheets that ship flat on pallets and fold up at the packing bench.
- Choose kraft vs white or printed top linerLeave the natural brown kraft liner bare for an earthy look, or specify a white or CMYK printed top card for bright retail contrast.
- Pair with honeycomb paper wrapCombine a die-cut honeycomb base tray with expandable custom honeycomb paper wrap on top for an all-paper glass shipper.
What are honeycomb inserts made of?
Which finishes can honeycomb inserts have?
Which structural features can I add to custom honeycomb inserts?
Honeycomb inserts specifications
| Spec | Options |
|---|---|
| Insert style | Honeycomb (structural hex-cell kraft board); also combinable with Card insert, EVA foam or EPE foam |
| Cavity counts | 1, 2-4, 5-12 or 13+ die-cut cavities, V-grooved fold-up cradles or 2-piece end caps |
| Panel thicknesses | Single-panel or multi-layer laminated honeycomb blocks |
| Liner & printing | Natural brown kraft or white liner; Full color (CMYK), Pantone or white ink on kraft via printed top liner |
| Finishes (on card top) | Matte, gloss, soft-touch, foil stamping, embossing, debossing, spot UV |
| Minimum order | Minimums depend on the product; we confirm yours with your quote; delivered within ±5% |
| Quantity presets | 250, 500, 1,000, 2,500+ inserts |
| Engineering & testing | Free structural design, CAD dieline, digital proof and 3D mockup; physical prototypes and drop/crush testing available |
| Turnaround & shipping | 10-14 business days (rush 4-5 days, quoted); free shipping to all 50 states, worldwide DDP available |
Ready to quote your honeycomb inserts? Compare up to 3 quantities with a free 3D mockup.
Request a Quote →What do brands pack inside custom honeycomb inserts?
Structural kraft honeycomb gives you the thick wall depth and vertical crush strength of foam in an all-paper construction that customers can toss straight into their household recycling bin along with the outer carton. Tell us the exact dimensions and weights of your jars, bottles or devices, and our design team will size the panel thickness, bridge spacing and base pad.
Honeycomb inserts design ideas
Example designs with made-up brands. Your packaging is made to your design.
What mistakes should you avoid when ordering custom honeycomb inserts?
Most honeycomb issues come from setting bridge walls narrower than one hex cell width. Avoid these five mistakes. When specifying custom printed honeycomb inserts, honeycomb inserts with logo, printed honeycomb inserts, branded honeycomb inserts and wholesale honeycomb inserts, avoid these common production mistakes
- Leaving under 0.625 inches of bridge width between heavy jars, which leaves an incomplete half-cell that crushes sideways.
- Cutting cavities with negative interference like foam instead of exact size or +1/32 inch clearance, catching on paper labels.
- Cutting through-holes in a single pad without bonding a bottom corrugated or honeycomb base pad underneath.
- Confusing rigid die-cut honeycomb board trays with expandable slit-kraft honeycomb wrapping paper when planning storage.
- Skipping semicircular finger lift cutouts beside snug jar cavities, forcing customers to tilt the box upside down.
Chat with a designer now
Share your logo, a sketch or an AI image. We'll rebuild every element cleanly onto your box dieline and send a 3D mockup, free.
Made your design with AI?
Generated a concept in Google Gemini, ChatGPT, Claude or Midjourney? Send us your AI image: we rebuild every element onto your box dieline and show you a 3D mockup before you pay, free.Custom die-cut honeycomb inserts vs plastic styrofoam and molded pulp: how do they compare?
| Plastic styrofoam or molded pulp | Custom honeycomb inserts from CubitPack | |
|---|---|---|
| Curbside disposal | Plastic EPS styrofoam or foam that customers dislike | All-paper kraft honeycomb that recycles with the outer box |
| Heavy jar protection | Thin single-wall card riser that buckles under 3 lb glass | Thick vertical hex-cell beams absorb corner and flat drops |
| Cavity fit | Loose crinkle paper or hand-wrapped bubble film | Die-cut wells and thumb notches tailored to your items |
| Brand alignment | Synthetic foam inside a natural kraft mailer | Warm organic kraft or printed card face matches your box |
| Tooling & setup | High mold fees for custom molded pulp trays | Zero die or plate charges on any cavity layout |
Get custom honeycomb inserts sized to your product, with a free 3D mockup before you pay.
Request a Quote →Are honeycomb inserts safe and sustainable?
High vertical compression strength
Upright hexagonal kraft cells act like miniature columns, resisting top-to-bottom pallet stacking loads and flat drops.Drop and crush testing available
Order a physical honeycomb prototype and optional drop and crush testing to verify glass or appliance survival before production.FSC paperboard & partner certifications
FSC-certified kraft liners and honeycomb cores plus ISO 9001 production are available on request through partner facilities.How do I order custom honeycomb inserts?
Tell us what you need
Size, quantities or AI conceptCompare volume pricing
Dedicated account managerApprove your proof
Digital proof + 3D mockupMade and shipped
Free to all 50 statesWhat affects the price of custom honeycomb inserts?
The price depends on four things, and every custom quote is free.
Panel thickness & layers
A single die-cut honeycomb pad or V-grooved cradle costs less than a 3-layer bonded blockOuter tray footprint (L × W)
Overall length and width determine how many inserts nest across a master honeycomb boardLiner stock & printing
Unprinted natural brown kraft liner costs less than a laminated CMYK or foil-stamped top cardOrder quantity
Unit cost drops across 250, 500, 1,000 and 2,500+ piece production tiersTo keep both unit cost and freight volume low, ask our design team if a V-grooved fold-up honeycomb cradle can protect your bottle or jar; V-grooved pads ship flat and fold into thick 3D bumpers at your packing table. Enter up to three quantities in the quote form to compare unit price breaks. You never pay die or plate fees, your first order is 10% off, and we beat any written US competitor quote. Buyers ordering bulk custom honeycomb inserts, personalized honeycomb inserts, custom size honeycomb inserts or wine, spirits, olive oil honeycomb inserts can compare up to three quantities in one quote.
10% off your first order.
Request a Quote →What do I need to send for a quote?
- The product and how many you need
- The inside size, or what goes in it
- A style, or ask us to suggest one
- Your logo or artwork (an AI image is fine)
- Pantone codes, if you have them
- Delivery ZIP code and the date you need it
Can I see a sample first?
Sample kit
Board and finish swatches, sample boxes, labels and bags. Credited to your first order.Digital proof + 3D mockup
See it before you payPrinted sample
Of your own designHow does shipping work?
- Free shipping to all 50 states
- Worldwide with DDP prices: duties and taxes included
- Blind and split shipping
- Damaged in transit? We reprint the damaged units free
Why brands choose CubitPack
Dedicated specialist
One account manager from quote to deliveryPantone guaranteed
Clearly off? We reprintReprint or refund
If we get it wrong, you chooseBBB accredited
A US business you can checkHoneycomb inserts questions
What is the difference between custom honeycomb inserts and custom honeycomb paper?
Custom honeycomb inserts are thick, rigid structural trays (0.4 to 2.0+ inches thick) with an internal hexagonal core sandwiched between flat linerboards, die-cut with cavities to hold products. Custom honeycomb paper is a thin slit-kraft sheet or roll that stretches by hand into a 3D mesh wrap.
Can kraft honeycomb inserts protect heavy glass bottles and candles as well as foam?
Yes, when engineered with the right wall width and base pad. Structural honeycomb has high vertical crush resistance and absorbs shock by controlled cell compression. For heavy glass jars or appliances, we use 0.75 to 1.0 inch perimeter walls and offer prototype drop testing.
What is the minimum order quantity for custom honeycomb inserts?
Minimums depend on the product; we confirm yours with your quote. Trial orders are reviewed case by case. Use the quick-add presets (250, 500, 1,000, 2,500) in Step 1 of the quote form to compare unit pricing.
Why are custom honeycomb inserts cheaper to tool than molded pulp trays?
Custom molded pulp requires expensive machined metal forming and drying molds that take weeks to tool. Custom honeycomb inserts are die-cut on flat-bed presses using standard steel-rule dies, and CubitPack charges zero die or plate fees.
How much space should be left between cavities on a honeycomb insert?
Keep at least 0.625 to 0.75 inches (16 to 19 mm) of bridge width between adjacent cutouts and around the outer perimeter. Because the internal core uses discrete hexagonal paper cells, wider bridges ensure complete hex cells support every divider wall.
Can you print my logo or product instructions on a custom honeycomb insert?
Yes. While standard honeycomb panels have a brown kraft or smooth white liner, we can print on the top liner or laminate a CMYK, Pantone or white-ink printed paperboard top-sheet over the tray.
How do you create stepped cavity depths in a honeycomb box insert?
We die-cut two or three honeycomb panels of specific thicknesses and bond them over a solid bottom honeycomb or corrugated base pad. That layered construction creates stepped cavity floors so short jars and tall bottles sit flush.
Do custom honeycomb inserts ship flat or at full thickness?
Multi-layer bonded honeycomb trays and block end caps ship at their full finished thickness, ready to drop into your boxes. V-grooved or scored honeycomb cradles can ship flat and fold up by hand along pre-cut hinge lines.
Are custom honeycomb box inserts recyclable in household paper bins?
Standard unlaminated kraft and white honeycomb inserts are made from paperboard liners, kraft core paper and water-based adhesive, so customers can place them in household cardboard recycling bins with the outer box.
How long do custom honeycomb inserts take to manufacture and ship?
Standard production takes 10 to 14 business days after digital proof approval and payment. Rush production in 4 to 5 business days is available for an extra cost quoted per order. Standard 50-state US shipping is free.
Still have a question? Ask a packaging specialist.
Request a Quote →Honeycomb inserts terms, explained
- Hexagonal kraft core
- The internal grid of vertical six-sided kraft paper cells that gives honeycomb board its crush strength
- Facing linerboard
- The flat top and bottom kraft or white paper sheets bonded to both sides of the hex core
- Cell size (diameter)
- The width across one hexagonal cell; smaller cells give firmer edges around small cavities
- V-groove hinge
- A V-shaped channel cut through one liner and core so a rigid honeycomb panel folds 90 degrees
- Flatwise crush strength
- The vertical load a honeycomb panel can support before the upright paper cells buckle
- Exposed-core cutout
- Peeling away the top paper liner in a zone to reveal the geometric honeycomb pattern
More for your candles packaging
Learn more
Get your honeycomb inserts price
One dedicated account manager prepares pricing across up to 3 quantities.
- Free design & AI-to-print studio + 3D mockup
- No die or plate charges · 4–5 day rush available
- Free shipping to all 50 states
- 10% off your first order
- Reprint or refund if we get it wrong
Every CubitPack fact on this page comes from our confirmed offers (honeycomb, card, EVA foam and EPE foam inserts, 10-14 business day turnaround, free structural design and free 50-state shipping) and was checked by a packaging specialist. Bridge-width and cell-support rules follow standard TAPPI and ISTA paper honeycomb converting practices. Tell us if something looks wrong.
Sources
- All CubitPack offers, inserts options (Honeycomb, Card insert, EVA foam, EPE foam; cavities 1, 2-4, 5-12, 13+; presets 250, 500, 1,000, 2,500), turnaround (10-14 business days, rush 4-5), free structural design and free US shipping
- Structural paper honeycomb panel construction, cell width geometry and flatwise crush properties
- Paper honeycomb perimeter buffer and drop-test cushioning guidelines for fragile glass and appliances
What changed
- October 22, 2026: First published.
- October 22, 2026: Updated specifications, terminology, and verified source links.